Anode effects spike energy costs. Pot instability triggers shutdowns. Die wear kills extrusion throughput. ProcessIQ diagnoses your aluminum plant equipment — smelting through surface treatment — with Hall-Héroult process knowledge built in.
Full coverage of aluminum production — from Hall-Héroult smelting through DC casting, rolling, extrusion, and surface treatment. ProcessIQ knows the failure modes at every stage.
Energy is 30–40% of your production cost. An anode effect, pot shutdown, or extrusion die failure hits profitability immediately. ProcessIQ shortens your diagnostic cycle.
Energy is the biggest cost lever in aluminum. Anode effects, unstable bath chemistry, and inefficient potroom operations directly inflate your energy cost per tonne. ProcessIQ diagnoses the root cause, not just the symptom.
Restarting a pot after instability or freeze costs $150K–$250K and takes weeks. Early diagnosis of bath chemistry imbalances, ledge conditions, and anode issues prevents the restart entirely.
New potline commissioning is a 3–6 month process where dozens of variables interact. ProcessIQ helps commissioning engineers diagnose unusual pot behavior during ramp-up without waiting for expert visits.
Die wear, incorrect billet temperature, and press parameter drift cause 40% of extrusion downtime. ProcessIQ isolates whether the root cause is the die, the billet, the press, or the quench system.
Start a free diagnostic on your aluminum plant equipment. Smelting, casting, rolling, extrusion — ProcessIQ covers it all.
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